Method for making integral brush and head unit



J. PACCIONE April 6, 1965 METHOD FOR MAKING INTEGRAL BRUSH AND HEAD UNIT Filed May 27, 1964 2 Sheets-Sheet 1 INVENTOR.

JOSEPH PACCIONE FIGJI F|G.I2

April 6, 1965 J. PACCIONE 3,177,038

METHOD FOR MAKING INTEGRAL BRUSH AND HEAD UNIT Filed May 27, 1964 2 Sheets-Sheet 2 ii 96b I J 92b "a HG- 1 SEPH PACCIONE lmllli lull. lihJlhmlhIL- INVENTOR United States, Patent This application is a continuation-in-part of my copending application, Serial No. 236,205, filed November 8, 1962, now abandoned.

This invention relates generally to a brush and the head unit thereof. More particularly, the invention relates to a brush and the head unit thereof for use in applying a liquid, such as paint, to a surface. Still more particularly, the invention relates to an integrally formed brush and head unit thereof and method for making the same, for use in the application of paint to a surface.

The general use and manufacture of brushes is well known in the prior art. However the construction and method of making prior art paint brushes has proved to have many inherent disadvantages. One of the dificulties with the prior art brushes is that they require excessive hold of the root end of the bristles within the ferrule. Another disadvantage relates to the use of auxiliary equipment which restricted decreasing the depth of hold since it would cause the non-parallel formation of the tuft of bristles, especially the inner ones. Some of the other prior art difficulties have resulted from: the use of inferior bonding agents or adhesives; the use of methods of brush construction in which prebonding of the bristle knot with adhesive outside the ferrule and thereafter forming thehold within the ferrul resulted in open spaces between the bristle knot and the ferrule since the bristle knot was not allowed to conform to the ferrule. Attempts to decrease the hold of the bristle knot within the ferrule of the prior art brushes below resulted in either the bristles falling out of the ferrule or in the bristles mushroomin (or flaring at the tip end thereof) followed by their falling out of the ferrule. When a twostep adhesive application was used in which a cap over the bristle knot within the ferrule was formed on the first step, followed by a second charge of adhesive prior to insertion of the handle, the result was a weaker structure, especially along the line where the cap and second charge joined, than which would be obtained by the single charge used in the present invention. Further, joining the handle, as was done in the prior art, by nailing it to the ferrule caused the brush to disintegrate and the components thereof to become disengaged from one another due to temperature and humidity causing unequal expansion and contraction of the joined components.

When the term minimal hold is used hereinafter under the present objects and advantage and in relation to the present invention, it shall be understood to mean the shortest possible hold necessary to keep the bristle knot within the ferrule and may be a hold as small as of an inch.

An object of the present invention is to provide an improved brush and head unit thereof, and method for making the same, which overcomes the prior art difficulties; which provides an effective hold by allowing the root end of the bristles within these ferrules to be flexible While obtaining a minimal hold of the bristle knot within the ferrule; which costs less :to make because it reduces the bristles within the ferrule to a minimal hold; which uses a reliable, economic and practical method of production.

Another object of the present invention is to provide an improved brush and head unit thereof, and method of making the same which is of stronger construction as it is integrally formed; which prevents mushrooming while 3,177fi38 Patented Apr. 6, 1965 obtaining a minimal hold of the bristle knot within the ferrule; which requires a single application of the bonding agent or adhesive to form an integral brush and eliminates the intermediate setting thereof while obtaining a minimal hold of the bristle knot within the ferrule; which is equally useable for all types of construction and brush end shapes; which uses an economically improved handle construction while obtaining a minimal hold of the bristle knot within the ferrule; and which insures parallel bristles in the tuft.

Other objects and advantages will be apparent from the following description of several embodiments of the invention and the novel features will be particularly pointed out hereinafter in the claims.

In the drawings:

FIGURE 1 is a perspective view, partly in section, of the improved head unit of the brush.

FIGURE 2 is an end view of a tuft of bristles.

FIGURE 3 is an end view of a tuft of bristles disposed within a ferrule.

FIGURE 4 is an end view in which strips have been inserted in the tuft of bristles.

FIGURE 5 is an end view showing the ferrule butted down on a level surface.

FIGURE 6 is an end view of a sizer.

FIGURE 7 is an end view showing preliminary sizing of the improved head unit.

FIGURE 8 is an end view showing the improved head unit being immersed in a mucilaginous solution.

FIGURE 9 is an end view of the improved head unit after the mucilaginous solution has dried.

FIGURE 10 is an end view of the improved head unit showing final sizing thereof.

FIGURE 11 is a sectional elevation View of the improved head unit.

FIGURE 12 is a front elevation, partly in section, of the improved head unit of FIGURE 11.

FIGURE 13 is a perspective view of an improved handle.

FIGURE 14 is another form of the improved head unit.

FIGURE 15 is a partial sectional elevation of an improved integrally formed brush.

FIGURE 16 is a front elevation, partially broken away, of an improved brush of FIGURE 15.

FIGURE 17 is a perspective view of a chisel shaped sizer.

FIGURE 18 is still another form of an improved head unit.

FIGURE 19 shows the improved head unit of FIGURE 18 being sized.

FIGURE 20 shows the improved head unit of FIGURE 18 disposed in a mucilaginous solution.

FIGURE 21 shows the improved head unit of FIGURE 18 after the solution has dried.

FIGURE 22 shows an end view, partially broken away, of the improved head unit of FIGURE 18.

FIGURE 23 shows another form of the improved handle.

FIGURE 24 shows a partial end View, partially in section of another form of the improved integrally formed brush.

FIGURE 25 shows a front elevation, partially broken away, of the improved integrally formed brush of FIG- URE 24.

In the embodiment of the invention shown in FIGURES 1-12, the novel head unit 46 is depicted with various auxiliary equipment and in a number of the steps of its construction. The improved head unit 4t as shown in FIGURE 1 comprises a ferrule 42 and a tuft or bunch of bristles 44 which are suitably joined to the ferrule by means of knot 46, as more fully described hereinafter. The general shape of the tuft 4-4 is fiat or square at its outer end. A handle 48 will subsequently be joined to i A to /2".

root end 52 and flag or tip end 54. The bristles may be either natural or synthetic.

In FIGURE 3 the tuft of bristles 44 is shown inserted I into the ferrule 42. Ferrule 42 has a handle end 58 and a root end 69, the outer end of which is designated generally as rim 62. Ferrule42 is usually formed of a metallic material, such as tin, but may also be formed of any other suitable material such as a plastic like nylon or the like.

In keeping with the common practice, strips 64 may be inserted as illustrated in FIGURE 4 in the root end 52 of tuft 44, which strips act to compress the root end 60 of the bristles thereby increasing frictional engagement of tuft 44 within ferrule 42. Strips64 may be formed of any suitable shape or material such as Wood, plastic, or metal.

Once the tuft of bristles is within the ferrule 42, with the bristles distributed along the whole Width of the ferrule 42, the root ends 52 are butted down against a flat or level surface so as shown in FIGURE 5 to render them even with the handle end 58 of ferrule 42 so as to initially give the tip end 54 of tuft 44 a flat trim.

Prior to sizing the tuft 44 of head unit 40 a mucilaginous solution 78 may be applied to the tip end 54 and body portion 50 of tuft 44 for purposes more fully described hereinafter. This will usually be done if the sizing operation for the brushes in question is to consist only of final sizing as explained hereinafter.

FIGURE 6 depicts a sizer 68'of typical construction having a base 70 to which is affixed column 72 of length L. Column 72 has a flat upper end 74'and is narrower than base'70, but its overall dimensions will be substantially similar to the inner dimensions of the ferrule 42, for reasons explained more fully hereinafter.

The length L of sizer 68'may be varied as desired. However the length L of sizer 68 will determine the length of hold H of the root end 52 of tuft 44 within ferrule 42.

In FIGURE 7, sizer 68 has been inserted into the handle end 58 of ferrule 42 for preliminary sizing so that its flat end 74 engages root end 52 of tuft 44 toforce tip end 54 to assume a similar flat shapeor fiat trim at outer end 76. It is noted that this fiat trim is substantially the same shape assumed by the tip end 54 on the tuft 44 being butted down within the ferrule 42 (see FIGURE 5). Preliminary sizing is an alternative method which may be used to form a hold H within the range of substantially But it will be possible in most instances to perform a single and final sizing as shown in FIGURE by the use of sizer 68a, having a column 72a of length L so as to form a hold H of not less than of an inch.

After the preliminary sizing shown in'FIGURE 7 or before the final sizing shown in FIGURE 10 the body. portion 50 and the tip end 54 of tuft 44 is dipped atleast one (1) ortwo (2) inches into a suitablemucilaginous solution 78, such as flaxseed or hair lacquer, heldwithin V suitable container as illustrated in FIGURE 8 and there- 7 after head unit 40 is removed from container 80. Of

course the final sizing operation can be done either before.

or after the mucilaginous solution 7 S has been applied but has been stated as being done before merely for convenience. 7

Once the flaxseed has been allowed to dry the tuft of bristles 44 will remain in'a'fixed or stiffened condition so that they will be self-supporting and will not fall apart.-

In this way the tuft of bristies 44 is allowed to maintain at the parallel relationship between the bristles thereof, both those inside the tuft 44 and those exposed outwardly thereof. The only noticeable change caused by the dried fiaxseed, as shown in FIGURE 9 will cause the tip end 54 to be slightly drawn in.

Whether or not the tuft of bristles 44 was sized preliminarily, they will now be sized finally as shown and described hereinbefore under FIGURE 10 to a hold of H In any event once tuft 44 has been sized finally, then as illustrated in FIGURE 11 a bonding agent or adhesive material 82 is poured or otherwise inserted over the root end 52 of tuft 44 within ferrule 42. The penetration or run of the adhesive material 82 will be approximately the depth of the hold H but may be greater or shorter depending on the density of the bristles in the root end 52. The excess of adhesive material 82 forms a cap 56 over knot 46. The adhesive material may be any suitable resin such as epoxy or may even be a suitable cement or cresol.

FIGURE 12 shows a completed head unit 40 in which the bonding agent 82 has penetrated the root end 52 of tuft 44 the length of hold H to form a knot 46'therewith and thereby secure the tuft 44 within ferrule 42. Thereafter any handle can be attached in any suitable manner to the improved head unit 40.

With the above described procedures the depth of the hold H may be made as small as A of an inch. Since bristles are the major cost component in brush making and can amount to as much as 50% of the total cost of the material, any saving thereof will appreciably affect the final cost of the brush. The paint brush purchaserv is concerned with the length of bristle exposed for painting. This is measured from the rim 62 where the bristle comes out of the ferrule 42 to the'tip end 54 of the bristle. The purchaser is not concerned with the depth of the hold H. Thus, by being able to make a brush having the hold as small as -of an inch, the maker thereof can accomplish appreciable saving, while producing a quality product.

In the embodiment of the invention illustrated in FIG- URES 13, 14, 15 and 16 another form of the novel brush is depicted and similar reference characters refer to similar parts described hereinbefore.

A novel handle 0 is shown in FIGURE 13 and includes an elongated holding portion 92 and a shank portion 94 which carries a pair of spaced downwardly extending flanges 96. A groove 98 is formed between has been sized to a depth of holds H which may be as small as 3 of an inch, and thereafter a larger than normal amount of adhesive material 82a was poured or inserted into ferrule 56 so as to form knot 46 and cap 56:: therein. It is noted that cap 56a is in the liquid state and of a larger quantity than cap 56 of FIGURE 11.

Then handle 9% is inserted into cap 56a of the adhesive material 82a so as to displace such material, which will be forced along the tapered outer sides of flange 96 and upwardly into groove 98. On hardening of the adhesive material 82a an integrally formed brush will be formed, asshown in FIGURE 16, wherein all the COD]: ponents are fixedly connected to each other.

In the embodiment of. the invention illustrated in FIG- URES 17 through 25 another form of the novel brush is shown, and similar reference characters will be used for the similar parts described hereinbefore.

FIGURE 17 shows'a sizer 68b having a base 70b and a column 7211 connected thereto, which column has a tapered or chisel shaped upper end 74b. Since it is the shape of the end 74b which determines the shape of the tip end of the brush, tip end 54b will assume a corresponding chisel shape 7612 as that of end 7417 of sizer 68b.

A tuft of bristles 44b is weighed to conform to the weight specification for the particular brush for which it is to be used and is disposed in ferrule 42b as shown in FIGURE 18.

After the tuft 44b is butted down within ferrule 42]; the handle end 5% thereof is pushed into sizer 6811 so that the tuft 44b forms a chisel shaped hold as illustrated in FIGURE 19 the smallest dimension of which is designated generally as H and may be as small as of an inch, with the peripheral or tapered edges Hi2 extending to a somewhat greater depth of hold corresponding to the tapered edges of upper end 741; of sizer 68b.

After the ferrule 42!; is removed from the sizer 681), the body portion 50b and tip end 54!) of head unit 4% is dipped into a mucilaginous solution 7% of container 80!) as shown in FIGURE for similar purposes as was described hereinbefore under FIGURE 8. Head unit 4% is withdrawn from container 801: and thereafter tuft 44b is allowed to dry. This will result in the bristles in tuft 44b forming into the parallel self-supporting mass depicted in FIGURE 21, having the previously described drawn in tip end 54b.

FIGURE 22 shows the application of a larger than normal amount of adhesive material 82b which penetrates the root end 5212 of tuft :4!) to form a knot 46b therewith and the excess amount thereof forms a cap 56b. Handle 9612 having a hand portion 9212, a shank portion 94b and a single downwardly extending flange 96b formed thereon as illustrated in FIGURE 23. Simultaneously with the formation of knob 46b, handle 9% is inserted into the cap 56b of liquid adhesive material @211 to displace the same about its tapered outer surface and flange 961') as shown in FIGURE 24.

The completed improved brush ltltlb is shown in FIG- URE 25 wherein the handle 90b, ferrule 56b and tuft of bristle 441; are integrally connected to one another by the adhesive material 82b to form a unitary structure.

It will be understood that various changes in the details, materials, arrangement of parts and operating conditions which have been herein described and illustrated in order to explain the nature of the invention may be made by those skilled in the art within the principles and scope of the invention as expressed in the claims.

What is claimed is:

1. A method for making a brush comprising the steps of:

(a) placing a tuft of bristles in a ferrule with the tip ends of the bristles extending outwardly from the ferrule,

(11) applying a mucilaginous materials on the tip ends of the bristles to fix their position,

(0) sizing the bristles within the ferrule to not less than a inch hold therein,

(d) applying a bonding agent to form a knot at the root end of the bristles within the ferrule.

2. A method for making a brush comprising the steps (a) placing a tuft of bristles in a ferrule with the tip ends of the bristles extending outwardly from the ferrule,

(b) applying a mucilaginous material on the tip end of the bristles to bind the bristles together and fix their position,

(0) sizing the bristles within the ferrule to not less than a & of an inch hold therein.

(d) applying a bonding agent to form a knot at the root end of the bristles within the ferrule,

(e) inserting a handle into the ferrule and extending into the bonding agent before the bonding agent has a chance to set, so that on its hardening the brush will be integrally formed.

3. A method for making a brush comprising the steps of:

(a) placing a tuft of bristles in a ferrule with the tip ends of the bristles extending outwardly from the female,

(b) a first sizing of the bristles within the ferrule to not less than a A of an inch hold therein,

(c) applying a removable mucilaginous material on the tip ends of the bristles to fix their position,

(d) a second sizing of the bristles within the ferrule to not less than V of an inch hold therein,

(e) applying a bonding agent to form a knot at the root end of the bristles within the ferrule.

4. The method for making a brush claimed in claim 3 wherein:

inserting a handle into bonding agent within the ferrule to form the brush.

5. The method for making a brush claimed in claim 3 wherein:

after placing the tuft of bristles into the ferrule, adding strips at the root end of the bristles whereby the bristles will be compacted to form a more secure knot therein.

6. A method for making a brush comprising the steps (a) placing a tuft of bristles in a ferrule with the tip ends of the bristles extending outwardly from the ferrule, l

(b) applying a mucilaginous material on the tip ends of the bristles to fix their position,

(c) sizing the bristles within the ferrule to a substantially of an inch hold therein,

([1) applying a bonding agent to form a knot at the root ends of the bristles within the ferrule.

7. A method for making a brush comprising:

(a) disposing a tuft of bristles in a ferrule whereby the tip ends of the bristles extend outwardly from the ferrule and the root ends of the bristles are butted down on a level surface,

(12) a first sizing of the root ends of the bristles within the ferrule to a hold therein within the range of A of an inch to A: of an inch,

(0) applying a removable mucilaginous material on the tip ends of the bristle and allowing it to harden so as to bind the bristles to each other,

(a!) a second sizing of the bristles within the ferrule to a of an inch hold therein.

(e) applying a bonding agent to form a knot at the root ends of the bristles within the ferrule.

8. The method for making a brush claimed in claim 7 wherein:

inserting a handle into the bonding agent within the ferrule to form the brush.

9. The method claimed in claim 8 wherein:

a flange extending from one end of the handle is inserted into the bonding agent.

References Cited by the Examiner UNITED STATES PATENTS 392,420 11/88 Fish 300-21 1,915,057 6/33 Foss 15193 1,923,884 8/33 Pushee 300-21 2,190,182 2/40 Beams 15---l93 GRANVILLE Y. CUSTER, 111., Primary Examiner. CHARLES A. WILLMUTH, Examiner. 

2. A METHOD FOR MAKING A BRUSH DCOMPRISING THE STEPS OF: (A) PLACING A TUFT OF BRISTLES IN A FERRULE WITH THE TIP ENDS OF THE BRISTLES EXTENDING OUTWARDLY FROM THE FERRULE, (B) APPLYING A MUCILAGINOUS MATEIAL ON THE PIPE END OF THE BRISTLES TO BIND THE BRISTLES TOGETHER AND FIX THEIR POSITION, (C) SIZING THE BRISTLES WITHIN THE FERRULE TO NOT LESS THAN A 1/32 OF AN INCH HOLD THEREIN. (D) APPLYING A BONDING AGENT TO FORM A KNOT AT THE ROOT END OF THE BRISTLES WITHIN THE FERRULE, (E) INSERTING A HANDLE INTO THE FERRULE AND EXTENDING INTO THE BONDING AGENT BEFORE THE BONDING AGENT HAS A CHANCE TO SET, SO THAT ON ITS HARDENING THE BRUSH WILL BE INTEGRALLY FORMED. 